Graco 311511G User Manual

Operation

Reactor A-20

Air Operated, Electrically Heated Plural Component Proportioner For spraying or dispensing 1:1 mix ratio materials, including epoxies and polyurethane foam. For professional use only.

Not approved for use in European explosive atmosphere locations.

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

See page 3 for a list of models and maximum working pressures.

US Patent No. 7822326 Russian Patent No. 2359181

311511G

ENG

TI8447A

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Typical Installation, without Circulation . . . . . . . . 7

Typical Installation, with Circulation . . . . . . . . . . . 8

Moisture Sensitivity of Isocyanates . . . . . . . . . . . . 9

Foam Self-Ignition . . . . . . . . . . . . . . . . . . . . . . . . 9

Isocyanate Hazard . . . . . . . . . . . . . . . . . . . . . . . 9

Keep Components A and B Separate . . . . . . . . . 9

Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 9

Component Identification . . . . . . . . . . . . . . . . . . . 10

Controls and Indicators . . . . . . . . . . . . . . . . . . . . 12

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 13

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Locate Reactor A-20 . . . . . . . . . . . . . . . . . . . . . 14

Determine Power Source . . . . . . . . . . . . . . . . . 14

Electrical Requirements . . . . . . . . . . . . . . . . . . 14

Configure to Supply Power . . . . . . . . . . . . . . . . 15

Ground System . . . . . . . . . . . . . . . . . . . . . . . . . 17

Iso Pump Lubrication System Setup . . . . . . . . . 17

Fluid Supply Connections . . . . . . . . . . . . . . . . . 17

Air Supply Connection . . . . . . . . . . . . . . . . . . . 17

Connect FTS and Heated Dual Whip Hose . . . 18

Recirculation / Pressure Relief Lines . . . . . . . . 19

Connect Heated Hose . . . . . . . . . . . . . . . . . . . . 19

Close Gun Fluid Manifold Valves A and B . . . . . 20

Connect Whip Hose to Gun Fluid Manifold . . . . 20

Pressure Check Hose . . . . . . . . . . . . . . . . . . . . 20

Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Fluid Temperature Sensor (FTS) Calibration . . . 21

Load Fluid with Feed Pumps . . . . . . . . . . . . . . . 21

Digital Temperature Controllers . . . . . . . . . . . . . 22

Over Temperature Alarms . . . . . . . . . . . . . . . . . 24

Fluid Heater Temperature Offset . . . . . . . . . . . . 24

Hose Heat Manual Mode . . . . . . . . . . . . . . . . . . 24

Supply Wet-Cups with Throat Seal Liquid . . . . . 25

Spraying Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Spray Adjustments . . . . . . . . . . . . . . . . . . . . . . 27

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Daily Start-up Procedure . . . . . . . . . . . . . . . . . . 29

Fluid Circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Circulation Through Reactor . . . . . . . . . . . . . . . 31

Circulation Through Gun Manifold . . . . . . . . . . . 32

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 36

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 36

Related Manuals

Reactor A-20 Repair/Parts Manual 311512

2 311511G

Systems

Maximum Fluid

Working Pressure

psi

System Part

AP3831 2000

(MPa, bar) Proportioner

253831 246678 246050 Fusion Air

(13.8, 138)

CS3831 2000

253831 246678 246050 Fusion CS CS01RD

(13.8, 138)

P23831 2000

253831 246678 246050 Probler P2 GCP2R1

(13.8, 138)

253831 Proportioner

This model is field-configurable to the following supply voltages: 230 V, 1 Phase 230 V, 3 Phase 380 V, 3 Phase

2,000 psi (14 MPa,140 bar) Maximum Fluid Working Pressure 120 psi (0.84 MPa, 8.4 bar) Maximum Air Working Pressure

Approvals:

Heated Hose Gun

50 ft (15 m) 10 ft (3 m) Model Part

246101

Purge

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311511G 3

Warnings

The following general warnings are for the setup, use, grounding, maintenance, and repair of this equipment. Additional, more specific warnings may be found throughout the body of this manual where applicable. Symbols

appearing in the body of the manual refer to these general warnings. When these symbols appear throughout the manual, refer back to these pages for a description of the specific hazard.

WARNING

ELECTRIC SHOCK HAZARD

Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power cord before servicing equipment.

• Use only grounded electrical outlets.

• Use only 3-wire extension cords.

• Ensure ground prongs are intact on sprayer and extension cords.

• Do not expose to rain. Store indoors.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDS’s to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

• Always wear impervious gloves when spraying or cleaning equipment.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

•Gloves

• Hearing protection

SKIN INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

• Engage trigger lock when not spraying.

• Do not point gun at anyone or at any part of the body.

• Do not put your hand over the spray tip.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or

servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

4 311511G

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.

• Ground all equipment in the work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

THERMAL EXPANSION HAZARD

Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure due to the thermal expansion. Over-pressurization can result in equipment rupture and serious injury.

• Open a valve to relieve the fluid expansion during heating.

• Replace hoses proactively at regular intervals based on your operating conditions.

Warnings

PRESSURIZED ALUMINUM PARTS HAZARD

Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical reaction and equipment rupture, and result in death, serious injury, and property damage.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• This equipment is for professional use only.

• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment and follow the Pressure Relief Procedure in this manual when equipment is not in use.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS forms from distributor or retailer.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

311511G 5

Warnings

WARNING

MOVING PARTS HAZARD

Moving parts can pinch or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.

BURN HAZARD

Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.

6 311511G

Typical Installation, without Circulation

Key for FIG. 1

A Reactor Proportioner BHeated Hose C Fluid Temperature Sensor (FTS) D Heated Whip Hose E Fusion Spray Gun F Proportioner and Gun Air Supply Hose G Feed Pump Air Supply Lines

H Waste Containers J Fluid Supply Lines K Feed Pumps L Agitator M Desiccant Dryer N Bleed Lines/Over Pressure Relief P Gun Fluid Manifold

FIG. 1: Typical Installation, without Circulation

ti8489a

* Shown exposed for clarity. Wrap with tape during operation.

311511G 7

Typical Installation, with Circulation

Key for FIG. 2

A Reactor Proportioner B Heated Hose C Fluid Temperature Sensor (FTS) D Heated Whip Hose E Fusion Spray Gun F Proportioner and Gun Air Supply Hose

G Feed Pump Air Supply Lines J Fluid Supply Lines K Feed Pumps L Agitator M Desiccant Dryer N Recirculation/Over Pressure Relief Return Hoses P Gun Fluid Manifold

FIG. 2: Typical Installation, with Circulation

ti8488a

* Shown exposed for clarity. Wrap with tape during operation.

8 311511G

Moisture Sensitivity of Isocyanates

Isocyanates (ISO) are catalysts used in two component foam and polyurea coatings. ISO will react with moisture (such as humidity) to form small, hard, abrasive crystals, which become suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity. If used, this partially cured ISO will reduce performance and the life of all wetted parts.

The amount of film formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature.

To prevent exposing ISO to moisture:

• Always use a sealed container with a desiccant

dryer in the vent, or a nitrogen atmosphere. Never store ISO in an open container.

• Keep the Iso (A) Pump Lube system jar 3/4 filled with clean Throat Seal Lubricant (TSL) 206995. Change whenever fluid appears cloudy.

Isocyanate Hazard

Spraying materials containing isocyanates creates potentially harmful mists, vapors, and atomized particulates.

Read material manufacturer’s warnings and material MSDS to know specific hazards and precautions related to isocyanates.

Prevent inhalation of isocyanate mists, vapors, and atomized particulates by providing sufficient ventilation in the work area. If sufficient ventilation is not available, a supplied-air respirator is required for everyone in the work area.

To prevent contact with isocyanates, appropriate personal protective equipment, including chemically impermeable gloves, boots, aprons, and goggles, is also required for everyone in the work area.

Keep Components A and B

• Use moisture-proof hoses specifically designed for ISO, such as those supplied with your system.

• Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.

• Never use solvent on one side if it has been contaminated from the other side.

• Always park pumps when you shutdown.

• Always lubricate threaded parts with Part 217374 ISO pump oil or grease when reassembling.

Foam Self-Ignition

Some materials may become self-igniting if applied too thick. Read material manufacturer’s warnings and material MSDS.

Separate

NOTICE

To prevent cross-contamination of the equipment’s wetted parts, never interchange component A (isocyanate) and component B (resin) parts.

Changing Materials

• When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.

• Always clean the fluid inlet strainers after flushing.

• Check with your material manufacturer for chemical compatibility.

• Most materials use ISO on the A side, but some use ISO on the B side.

• Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the B (resin) side.

311511G 9

Component Identification

ti8447a

ti8448a

ti8481a

FIG. 3: Typical Installation

10 311511G

Key:

Component Identification

R Main Disconnect Switch - Controls power to all

circuits. It must be ON for proportioning unit to operate. Temperature displays are lit when main switch is ON.

S Main Air Filter - Filters system air supply.

T Resin (B) Pressure Gauge - Displays pressure in

resin proportioning system (B side).

U Resin (B) - Inlet Supply Valve

V Resin (B) Fluid Y-Strainer

W ISO (A) Pressure Gauge - Displays pressure in

isocyanate proportioning system (A side).

X ISO (A) - Inlet Supply Valve

Y ISO (A) Fluid Y-Strainer

Z ISO (A) Pump Lube System - (A side only)

AH Resin (B) Proportioning Pump - Draws in and

dispenses a fixed volume of resin to gun.

AI Power-Lock

™

Hose Heat Connection - Connects

power to heated hoses.

*AJ Primary Heater Over-Temperature Switch -

Sends signal to temperature controller if heater exceeds maximum temperature condition.

AK Resin (B) Pump Wet Cup - Access for daily wet

cup refill.

DD Air Inlet Ball Valve - (3/8 NPT male fitting)

FF ISO (A) Inlet - Fitting (1/2 swivel fitting)

GG Resin (B) - Inlet (3/4 swivel fitting)

* Components not shown.

AA ISO (A) - Packing Nut and Lube Cup - (A side

only)

*ABPressure Limit Switches - Factory set to turn off

air drive system when proportioning pump exceeds designed operating pressure limit.

*ACPrimary Heater Thermocouple - Senses

temperature of primary heater and inputs that information.

AD FTS Jumper Harness - Carries electrical signal

from FTS sensor in isocyanate hose to hose temperature controller.

*AEAir Motor Reversing Switch - (Front of air motor)

Energizes and de-energizes air solenoid valve coils to reverse direction.

*AFPrimary Heater - Heats material to required

dispensing temperature.

AG ISO (A) - (Isocyanate) Proportioning Pump -

Draws in and dispenses a fixed volume of isocyanate to gun.

311511G 11

+ 25 hidden pages